Design, Manufacturing & Testing of Captive Power Plant Using Liquid Coolant Jet

ISSN (Online) 2321-2004
IJIREEICE ISSN (Print) 2321- 5526
International Journal of Innovative Research in

Electrical, Electronics, Instrumentation and Control Engineering
ISO 3297:2007 Certified
Vol. 6, Issue 04, April 2018
Design, Manufacturing & Testing of Captive

Power Plant Using Liquid Coolant Jet
Prof. Pooja P. Kulkarni1, Mr. Rohit C. Chavan2, Mr. Tushar B. Ransing3, Ms. Tejaswini V. Khot4
Assistant Professor, Electrical Engineering Department, NBN Sinhgad School of Engineering, Pune, India1
Student, Electrical Engineering Department, NBN Sinhgad School of Engineering, Pune, India2,3,4
Abstract: Captive Hydropower plant is the Low cost way to generate electricity present day. It is the best source of
non-conventional energy. India is developing nation with the growth in population and upsurge in the utilization of
electricity is tremendously increasing at an upsetting rate. The following paper explains an idea about efficient use of
liquid coolant jet to generate electricity using an open loop coolant flow which gives most economical solution for
provincial electrification purpose at Cummins PHP plant. This is achieved by allowing the liquid coolant jet to fall on
low head open type water turbine coupled to alternator by means of gear pulley mechanism. The generated electrical
energy is fed to lighting load. The working principle, functioning, design with calculations and applications along with
future scope of captive power plant has been explained in this paper.
Keywords: Nozzle, Turbine, Alternator, Coolant Jet, Gear Pulley.
I. INTRODUCTION
Electricity generation using cogeneration captive power generation. Energy conservation is a few solutions to resolve
this problem to some extent. Energy is most important and one of the biggest factor for Nation’s economy. The need of
electricity has been increased vastly at Industry level, Commercial level and Residential level. Electricity plays a role in
Human development; it has to serve different purposes of human being (E.g. - Lighting, Refrigeration, Household and
Industrial appliances). Technology has made the life very reliable and comfortable, but it results in higher consumption
of the electricity.
While electricity generation is not able to cope up with the increased demand of electricity. Now, Private industries are
taking care of saving an electricity as well as electricity bill by implementing various types of captive power plants. It
directly gives benefits to industries and government by saving on fuel required to generate electricity since it has been
seen from past decades that natural resources are getting drained very terribly.
Captive power plants are the power plants set by any person or group of industries to generate electricity for its own
resource. It also includes power plant set up by an association or co-operative society. Captive power is the plant that
generates required power by itself to the plants by using its own by-product for power generation. By-product can be
anything like liquid coolant, water, bagasse, Heat.
II. WORKING OF CAPTIVE HYDROPOWER PLANT
A captive power plant is a facility that is dedicated for providing a localized source of power to an energy user. These
are typically industrial facilities or large offices. The captive hydropower plant described here has used the liquid
coolant of the assembly line of industry. The potential energy of liquid coolant is converted into kinetic energy by using
convergent nozzle. The converted kinetic energy of liquid coolant is fed to low head open type water turbine which
converts input into mechanical energy. The produced mechanical energy is given to alternator and alternator generates
electricity, which is used further for Industrial lighting load.
Copyright to IJIREEICE DOI 10.17148/IJIREEICE 1


III. CAPTIVE HYDROPOWER PLANT CLASSIFICATION
The Captive Hydropower Plant can be classified to two categories:- large hydropower plant and small hydropower
plant. The categories vary depending on countries and norms they follow. The table below gives the classification of it.
Type Capacity
Large hydro power plant Above 100 MW.
Medium hydro power plant 15 to 100 MW.
Small hydro power plant 1 to 15 MW.
Mini hydro power plant Above 100 KW and below

1 MW
Micro hydro power plant From 5KW to 100 KW
Pico hydro power plant From a few hundred watts

up to 5kW
Table1-Classification of Hydropower Plants
IV. PRINCIPLE OF PICO HYDRO POWER PLANT
The plant designed by us is a PICO hydro power plant. Generation of electricity from liquid coolant mainly depends
upon head and flow of liquid coolant. Both must be required to be available for the generation of electricity. Liquid
coolant at Cummins PHP plant is diverted from an assembly line towards the filtration plant and then through the
nozzle and turbine. The pressure of liquid coolant at the end of coolant jet depends on vertical distance i.e. head. This
pressurized liquid coolant creates force on turbine buckets and drives the turbine. The turbine coupled to an alternator
then electricity is produces. Amount of electricity produced depends on quantity of flow of liquid coolant and available
head at Cummins PHP site.
The electric power (theoretical) produced i.e. output at the given head corresponding to a input coolant is given by
P = Q × H × e × g in Kilowatts (kW)
Where,
P = Power output in KW.
H = Head available at site in meter.
Q = Flow in outlet pipe, in meter cube per second (m3/s)
e = Efficiency of the power plant considering total head loss and efficiency of the turbine and generator, expressed by a
decimal (e.g. 85% efficiency= 0.85)
g = 9.81 (constant) is the product of density of water and acceleration due to gravity.
This available energy is converted into mechanical energy using hydro turbine.
V. LIQUID COOLANT FILTRATION PLANT AT SITE
Filtration plant basically for the reuse of liquid coolant, it filter outs chips and oil comes from assembly line of
Cummins PHP. The dirty liquid coolant came from industry is fed into dirty tank through the outlet pipe having
diameter of 600 mm. The dirty tank has magnetic conveyor inside it, which attracts the entire unwanted chip and
throws out in a container.
The Procedure of Filtration Plant is explained below:

1. Contaminated coolant enters into the drag conveyer via a toughing system. The continuously operating
conveyer removes the bulk of the cheap load.
2. Metal chips are stripped out by the filter element as the coolant passes through.


3. The suction which draws the coolant through the element holds these chips on the surface of the wedge wire
screen.
4. As the chip cake builds on the wedge wire screen, so does the resistance to coolant flow. The resistance to
flow is measured by the vacuum builds up until it reaches suction of the system pump.
5. A vacuum is builds up until it reaches a pre-set point (3mtr). Then the filter automatically indexes.
6. It should be noted that a 10% excess flow is generated by the system pump and allowed to weir into the
generation tank of the filter unit. This maintains the level in the clean tank of the filter unit
Fig.1: Coolant Filtration Plant
VI. STUDY OF DISCHARGE
Cummins PHP has coolant filtration plant to supply liquid coolant to its high horsepower engine manufacturing
assembly line. The capacity of coolant tank is 130000 litres. This coolant is filtered by three processes and circulated
throughout the assembly line with the help of four 75HP motors which gives flow discharge of 11000 litres per minute.
The available head due to the outlet pipe is of 1.5 meters from the top surface of the coolant tank.
Fig.2: Coolant Filtration Jet


VII. STUDY OF SELECTION OF NOZZLE
The nozzle is selected according to the required speed of turbine and the available flow rate. It must fit in the available
space above the tank.
Fig.3: Convergent Nozzle
VIII. DESIGN RESULTS OF THE TURBINE
Design of Open Type Low Head Turbine
Input Parameters
Discharge = 7400 litres per minute (0.1258 m3/s)
Head = 1.5 meters (5 feet)
DESIGN PARAMETER UNIT OF

PARAMETERS OUTPUT PARAMETERS
1) Hydraulic 1.851 KW
Power
2) Velocity of Jet 4.341 m/s
(V1)
3) Diameter of Jet 196.092 mm
(d)
4) Mass Flow 183.19 Kg/sec
Rate
5) Normal Force 2.0834 m/s
Exerted On
Vanes
6) Normal Force 827.139 N
7) Power Output 1.723 KW
8) Hydraulic 93.10 %
Efficiency
Table2- Design Results of the Turbine


IX. CALCULATIONS FOR THE SELECTION OF ALTERNATOR DESIGN

Assumptions:
1. Specific Electric Loading(ac) = 20000 to 40000 A/m
2. For Specific magnetic Loading (Bav) Air Gap Flux Density = 0.52 to 0.65 Wb/m2
3. Winding Factor (Kw) = 0.995
4. Ratio L/t = 0.6 to 0.7
5. Synchronous speed = 1500 rpm
6. 10 KVA, 0.8 P.F
Solution:
1. Synchronous Speed =1500/60
= 25 r. p. s
2. No. of poles = 2 × 50/25
=4
3. Average Flux Density = Bav = 2/π × 0.55
= 0.3501 Wb/m2
4. C0 =11 × 𝐵𝑎𝑣 × 𝑎𝑐 × 𝐾𝑤 × 10-3
=11 × 0.3501 × 20000 × 0.995 ×10-3

C0 = 76.63
5. D2L = Q0/C0× Ns
= 10/76.63×25
D2L = 5.2198×10-3
Taking,
L/ t = 0.65
L = 0.65×(π/P)× D
L = 0.510D
D2L = 3.47×10-3
0.510×D3 = 3.47×10-3
D = 0.1894 m
L = 0.510×0.1894
L= 0.0965 m
Kw = 0.995
6. Peripheral Speed (Va) = π × D × Ns

= π × 0.1894 × 25
= 14.875 m/s
7. Q0 =1.11 × Bav × ac × Kw ×10-3×Va×2×L/ns
=1.11 × 0.3501 × 20000 × 0.995 ×10-3×(14.875)2×0.0965/25
= 6.604 KVA
8. Q0 = 6.604×0.8
= 5.28 Kw
Electric Air Gap Output D2L Q0 (KVA) Q0 (Kw)

Loading (ac) Density Coefficient (C0)
20000 0.55 76.63 5.21×10-3 6.60 5.28
30000 0.55 115 3.47×10-3 9.95 7.96
38000 0.60 158.461 2.524×10-3 13.72 10.97
Table3- Varying Range of Power Output


X. BLOCK DIAGRAM
Fig.4: Captive power plant generation using liquid coolant jet
XI. RESULTS
1. Maximum Power which can be generated using maximum flow rate of coolant. 5kW
2. Observation Table
Flow Rate Speed of Alternator Voltage
11000 Lps 1500 Rpm 230 Volts
3. After load connection
Voltage Current Speed Frequency
220≈230 Volt 27.2 Amp 1450≈1500 Rpm 49≈51
4. Maximum load which can be supplied. 4kW
Table4- Result Table of Project


XII. COSTING OF PROJECT
1. Turbine RS. 41100/-
2. Alternator RS. 32000/-
3. Nozzle RS. 4300/-
Table5- Costing of Project
XIII. CONCLUSION
We conclude that low head open type Water wheel turbine is a best suitable and efficient option for head produced due
to coolant jet. It is also helpful for head imparted by waste water in city area to produce electricity for small scale
application. This paper reviews the Captive power generation from coolant jet. This paper can be a guideline for the
developers in implementing captive hydro power plant for available low head of coolant jet.
REFERENCES
[1] Pritam Patil, Ajit Pawar, Amol Swami, “The Coolant Filtration Plant”, Cummins HPP, Pvt, Ltd., 2010.
[2] D. B. Patil, R. A. Oak, “Captive power plant- A case study of CEPT Ichalkaranji, Maharashtra”, IJRET, Volume 1, Issue 3, 2016.
[3] Dr. R. K. Bansal, “Fluid mechanics and hydraulic mechanics”, Revised Ninth Edition, Laxmi Publcations Pvt. Ltd., 2010.
[4] A. K. Sawhney, ”Electrical Machine Design”, Sixth Edition, Dhanpat Rai & Co., 2013.
[5] Lie Jasa, I Putu Ardana, “A New Design of Banki’s Water Turbine Model for
Pico Hydro in Tabanan Bali”, ISBN: 978-1-5090-2690-6 Bali, 6 - 8 October 2016, ICSGTEIS 2016.
[6] Praful Yelguntwar, Pranay Bhange, Yogesh Lilhare, Ankit Bahadure, “Design, Fabrication & Testing Of A Waterwheel For Power
Generation’, In An Open Channel Flow IJREAT International Journal of Research in Engineering & Advanced Technology, Volume 2, Issue
1, Feb-Mar, 2014 ISSN: 2320 – 8791.
[7] V.B.Bhandari, Design of Machine Element,Design of shaft and Selection of Bearing from Manufacturer’s Catalogue.
[8] Kalpesh Dange, Tejas Barhate, Dipti Malaye, Sanket Narwade, “Design and Modeling of Low Power Alternator for Solar Thermal
Application”, International Conference on Nascent Technologies in the Engineering Field (ICNTE-2017).
[9] Fraenkel, P., Paish, O., Bokalders, V., Harvey, A., Brown, A., & Edwards, R. (1991). In Fraenkel P., Stockholm Environment Institute. (Eds.),
Micro-hydro power : A guide for development workers. London: Immediate Technology Publications in association with the Stockholm
Environment Institute.
[10] Md. Zubaer Eibna Halim, M. S. Alam, and Kazi Khairul Islam,”Study on Gas Based Captive Power Generation in Bangladesh”, Proceedings of
2013 2nd International Conference on Advances in Electrical Engineering (ICAEE 2013)19-21 December, 2013, Dhaka, Bangladesh.

Design, Manufacturing & Testing of Captive Power Plant Using Liquid Coolant Jet

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Design, Manufacturing & Testing of Captive Power Plant Using Liquid Coolant Jet

Caricato da

Copyright:

Formati disponibili

ISSN (Online) 2321-2004

IJIREEICE ISSN (Print) 2321- 5526

International Journal of Innovative Research in